A photovoltaic module laminator and defoaming device therefor

Abstract

The present application relates to photovoltaic module processing technical field, specifically to a kind of photovoltaic module laminator and its defoaming device.Photovoltaic module laminator includes laminator box body, the laminator box body is divided into vacuum cavity, defoaming cavity and curing cavity, defoaming cavity is equipped with defoaming device, the defoaming device includes power mechanism, is fixed in the defoaming cavity;Lever mechanism is connected to power mechanism, downwardly acts on photovoltaic module;The top of power mechanism is equipped with moving ring, and the moving ring carries out variable-diameter circumferential motion;The present application sets up separate defoaming cavity in laminator, after photovoltaic module is laminated, using defoaming device in defoaming cavity to carry out extrusion defoaming to it, the lever mechanism specially provided in the defoaming device can make the pressure rod variable-diameter circumferential motion on the surface of photovoltaic module, and the pressure rod carries out helical motion from the center of photovoltaic module to all around, cooperate with the rotary motion of pressure rod itself, can gradually extrude the bubble on the surface of photovoltaic module from all around, guarantee photovoltaic module finished product quality.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module processing technology, specifically to a photovoltaic module laminator and its defoaming device. Background Technology

[0002] In the manufacturing process of photovoltaic modules, lamination is a core process. Using a laminator, a stacked structure consisting of front glass, back glass, solar cells, and encapsulating film is pressed into a single unit. This protects the solar cells from external environmental influences during power generation, extending the lifespan of the photovoltaic module. The lamination process has extremely high requirements for vacuum level, heating temperature, and pressure. Insufficient vacuum or uneven heating plate temperature can easily lead to air bubbles forming inside the photovoltaic module.

[0003] Chinese invention patent CN115416389A discloses a lamination device and lamination process for photovoltaic modules. The lamination device controls the shape of a rubber sheet so that the rubber sheet first comes into contact with the photovoltaic module from the middle, thereby further expelling air bubbles inside the photovoltaic module.

[0004] The rubber sheet in this device is still a large pressing surface, which cannot guarantee that the air bubbles will be pressed from the center to the periphery when it comes into contact with the surface of the photovoltaic module. Consequently, the air bubble elimination effect of the laminating device cannot be guaranteed. Therefore, the photovoltaic module laminating machine needs to be improved. Summary of the Invention

[0005] The purpose of this invention is to provide a photovoltaic module laminator and its defoaming device to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a defoaming device for a photovoltaic module laminator, placed inside the defoaming chamber of the photovoltaic module laminator, comprising:

[0007] The power mechanism is fixed to the defoaming chamber;

[0008] The lever mechanism, connected to the power mechanism, acts downwards on the photovoltaic module;

[0009] The top of the power mechanism is provided with a movable ring, which performs a variable-diameter circular motion;

[0010] The lever mechanism includes a connecting rod, one end of which has a small ball joint and the other end has a large ball joint. The small ball joint is located inside the moving ring, and the large ball joint is located inside the power mechanism.

[0011] Preferably, the bottom of the large ball joint is provided with a connecting arm, the end of the connecting arm is provided with a pressure rod, and the end of the pressure rod is provided with a scraper.

[0012] Preferably, the photovoltaic module is placed on a second platform, which is equipped with a vacuum suction cup.

[0013] The present invention also provides a technical solution: a photovoltaic module laminator, including a laminator housing, wherein the laminator housing is divided into a vacuum chamber, a defoaming chamber and a curing chamber, and the defoaming chamber is provided with a defoaming device.

[0014] Preferably, the vacuum chamber is equipped with a vacuum system, a heating system, and a pressurization system. The vacuum chamber is divided into an upper chamber and a lower chamber. A first platform is provided in the lower chamber. Multiple auxiliary conveyor bars are provided below the first platform. Each auxiliary conveyor bar includes two support frames. Both ends of the support frames are provided with conveyor rollers. A conveyor belt is wound around the conveyor rollers. The first platform has an opening at the corresponding position of each auxiliary conveyor bar, and the top surface of the conveyor belt is flush with the top surface of the first platform.

[0015] Preferably, the vacuum system includes an air inlet located on the inner wall of the upper cavity and an air extraction port located on the inner wall of the lower cavity. The air inlet is controlled by an air pump, and the air extraction port is controlled by a vacuum pump.

[0016] Preferably, the pressurization system includes a pressure plate, the four sides of which are completely fitted against the inner wall of the upper cavity, and the pressure plate is connected to the top of the upper cavity by a plurality of spring rods.

[0017] Preferably, the heating system includes an electric heater and a heat-conducting pipe, the heat-conducting pipe being laid flat inside the first platform and avoiding the openings in the first platform.

[0018] Preferably, the curing chamber is equipped with a conveyor and a temperature control system.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] A separate defoaming chamber is set up in the laminator. After the photovoltaic module is laminated, the defoaming device in the defoaming chamber is used to squeeze and defoam it immediately. After defoaming, it is cured to ensure that no bubbles appear on the surface of the finished photovoltaic module.

[0021] The defoaming device features a specially designed lever mechanism that allows the pressure rod to move in a variable-diameter circular motion on the surface of the photovoltaic module. The pressure rod moves spirally from the center of the photovoltaic module outwards, while the pressure rod itself also rotates, which can gradually squeeze out the air bubbles on the surface of the photovoltaic module from all sides.

[0022] The defoaming device can also eliminate bubbles by using a rotating turntable to drive the photovoltaic modules fixed on the turntable to rotate. During the rotation, the pressure rods squeeze the bubbles, thus ensuring the quality of the finished photovoltaic modules. Attached Figure Description

[0023] Figure 1This is a schematic diagram of the internal structure of the laminator of the present invention;

[0024] Figure 2 This is a schematic diagram of the internal structure of the vacuum chamber of the laminator of the present invention;

[0025] Figure 3 This is a schematic diagram of the auxiliary conveyor bar structure in this invention;

[0026] Figure 4 This is a schematic diagram of the internal structure of the first platform in this invention;

[0027] Figure 5 This is a schematic diagram of the internal structure of the defoaming chamber in Embodiment 1 of the present invention;

[0028] Figure 6 This is a schematic diagram of the moving ring structure in Embodiment 1 of the present invention;

[0029] Figure 7 This is a schematic diagram of the spiral guide rail structure in Embodiment 1 of the present invention;

[0030] Figure 8 This is a schematic diagram of the top structure of the hydraulic platform in Embodiment 1 of the present invention;

[0031] Figure 9 This is a schematic diagram of the lever mechanism in operation according to Embodiment 1 of the present invention;

[0032] Figure 10 This is a schematic diagram of the second platform structure in Embodiment 1 of the present invention;

[0033] Figure 11 This is a schematic diagram of the internal structure of the defoaming chamber in Embodiment 2 of the present invention;

[0034] Figure 12 This is a schematic diagram of the turntable structure in Embodiment 2 of the present invention;

[0035] The components include: a laminator housing 1, a feed door 11, a discharge door 12, a feed conveyor belt 13, and a discharge conveyor belt 14; a vacuum chamber 2, a first platform 21, an auxiliary conveyor bar 22, a support frame 221, a conveyor roller 222, a conveyor belt 223, an air inlet 231, an air extraction port 232, a pressure plate 241, a spring rod 242, and a heat-conducting pipe 25; a defoaming chamber 3, a hydraulic rod 311, a hydraulic platform 312, a spiral guide rail 3121, a rack 3122, a moving ring 313, a gear shaft 3131, a connecting rod 314, a small ball joint 315, a large ball joint 316, a connecting arm 317, a pressure rod 318, a scraper 319, a second platform 32, a vacuum suction cup 33, and a turntable 34; a curing chamber 4, a conveyor table 41; and a photovoltaic module 5. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] A photovoltaic module consists of, in order, tempered glass, EVA film, solar cells, EVA film, and backsheet, wherein the EVA (ethylene / vinyl acetate copolymer) film is used as a hot melt adhesive.

[0038] Please see Figure 1 The present invention provides a technical solution: a photovoltaic module laminator, including a laminator housing 1, with a feed door 11 and a discharge door 12 on both sides of the laminator housing 1, a feed conveyor belt 13 on one side of the feed door 11, and a discharge conveyor belt 14 on one side of the discharge door 12, wherein the photovoltaic modules 5 after being stacked and laid enter the laminator housing 1 through the feed door 11.

[0039] The laminator housing 1 is divided into a vacuum chamber 2, a defoaming chamber 3, and a curing chamber 4. Each chamber is separated by a door to ensure the sealing of each chamber. The feed door 11, the discharge door 12, and each chamber door are all electric lifting doors and are equipped with sealing strips.

[0040] The vacuum chamber 2 is equipped with a vacuum system, a heating system, and a pressurization system.

[0041] Please see Figure 2-3 The vacuum chamber 2 is divided into an upper chamber and a lower chamber. The lower chamber is equipped with a first platform 21. Below the first platform 21, there are multiple auxiliary conveyor bars 22. Each auxiliary conveyor bar 22 includes two support frames 221. Both ends of the support frames 221 are equipped with conveyor rollers 222. A conveyor belt 223 is wound around the conveyor rollers 222. The first platform 21 has an opening at the corresponding position of each auxiliary conveyor bar 22. The top surface of the conveyor belt 223 is flush with the top surface of the first platform 21. The conveyor rollers 222 are controlled by a CNC system. The rotation of the conveyor rollers 222 drives the conveyor belt 223 to rotate, thereby moving the photovoltaic module 5 on the first platform 21.

[0042] The vacuum system includes an air inlet 231 located on the inner wall of the upper cavity and an air extraction port 232 located on the inner wall of the lower cavity. The air inlet 231 is controlled by an air pump, and the air extraction port 232 is controlled by a vacuum pump. After the photovoltaic module 5 enters the housing, the vacuum pump controls the air in the housing to be extracted to form a vacuum environment, so that the air between the layers of the photovoltaic module 5 is initially discharged and a pressure difference is formed, which facilitates the lamination of the pressurization system. While the vacuum chamber is being evacuated, the vacuum chamber is heated by the heating system.

[0043] The pressurization system includes a pressure plate 241, the four sides of which are completely fitted to the inner wall of the upper cavity. The pressure plate 241 is connected to the top of the upper cavity by multiple spring rods 242. Compressed gas is introduced into the upper cavity by an air pump to pressurize the upper cavity, causing the pressure plate 241 to gradually descend and apply pressure to the photovoltaic module 5, thereby completing the lamination of the photovoltaic module 5.

[0044] Please see Figure 4 The heating system includes an electric heater and a heat pipe 25. The heat pipe 25 is laid flat inside the first platform 21 and avoids the opening of the first platform 21. The electric heater energizes the heat pipe 25 to heat the photovoltaic module 5 placed on the first platform 21, so that the EVA film layer in the photovoltaic module 5 melts, thereby bonding the battery cell with the tempered glass and the back sheet together.

[0045] After being defoamed in the defoaming chamber 3, the laminated photovoltaic module 5 enters the curing chamber 4. The curing chamber 4 is equipped with a conveyor 41 and a temperature control system. The conveyor 41 is used to transport the photovoltaic module 5. The temperature control system lowers the temperature in the curing chamber 4 to achieve the curing effect, allowing the laminated photovoltaic module 5 to cool and solidify, and finally be transported out from the discharge port 12.

[0046] The present invention also provides a technical solution: a defoaming device for a photovoltaic module laminator, wherein the defoaming device is disposed in the defoaming chamber of the photovoltaic module laminator provided by the present invention. Example 1

[0047] Please see Figure 5 In this embodiment, the power mechanism includes multiple hydraulic rods 311, which are fixed to the top of the defoaming chamber 3. The ends of the hydraulic rods 311 are connected to a hydraulic platform 312. The height of the hydraulic platform 312 is adjusted by adjusting the length of the hydraulic rods 311, so that the scraper 319 is in close contact with the surface of the photovoltaic module 5.

[0048] Please see Figure 6-8 The hydraulic platform 312 has two spiral guide rails 3121 on its top. The inner wall of the spiral guide rails 3121 is evenly distributed with racks 3122. The spiral guide rails 3121 are provided with moving rings 313 inside.

[0049] The bottom of the moving ring 313 is provided with two symmetrical gear shafts 3131. The gear shafts 3131 are embedded in the moving ring and rotated by a CNC system. The gear part of the gear shaft 3131 meshes with the rack 3122 on the inner wall of the spiral guide rail 3121. Through the rotation of the gear shaft 3131 itself, the gear shaft 3131 moves within the spiral guide rail 3121.

[0050] Please see Figure 9 The hydraulic table 312 has a circular hole in the center, and a lever mechanism is installed inside the circular hole. The lever mechanism includes a connecting rod 314, one end of which has a small ball joint 315 and the other end has a large ball joint 316. The large ball joint 316 is located inside the circular hole and can rotate freely within the circular hole. The bottom of the large ball joint 316 has a connecting arm 317, and the end of the connecting arm 317 is hinged to a pressure rod 318. The end of the pressure rod 318 has a scraper 319. The pressure rod 318 is controlled by a CNC system and can rotate. The small ball joint 315 is located inside a moving ring 313. The small ball joint 315, the connecting rod 314, the large ball joint 316 and the connecting arm 317 are integrally formed. The small ball joint 315 moves through the variable diameter circular motion of the moving ring 313, and the large ball joint 316 transmits the movement of the upper and lower parts of the rod, thereby causing the connecting arm 317 to perform a reverse variable diameter circular motion.

[0051] Before defoaming, the gear shaft 3131 is located at the center of the spiral guide rail 3121. The gear shaft 3131 first rotates clockwise. At this time, the moving ring 313 moves from the center of the spiral guide rail 3121 to the outer ring, thereby driving the connecting arm 317 to rotate counterclockwise, and the rotation radius gradually increases. Together with the self-rotating pressure rod 318, it presses and defoams the photovoltaic module 5. The defoaming path unfolds spirally from the center of the photovoltaic module 5 to the surrounding areas, so that the bubbles in the photovoltaic module 5 are squeezed out from the middle to the four sides, ensuring the defoaming effect.

[0052] After defoaming is completed, the gear shaft 3131 rotates counterclockwise, driving the moving ring 313 to move from the outer ring of the spiral guide rail 3121 to the center and return to the initial position. At this time, the connecting arm 317 also returns to the center.

[0053] Please see Figure 10 The defoaming chamber 3 is provided with a second platform 32, and a plurality of auxiliary conveying strips 22 are provided below the second platform 32. The second platform has an opening at the corresponding position of each auxiliary conveying strip 22. The auxiliary conveying strips 22 have the same structure and working principle as the auxiliary conveying strips 22 in the vacuum chamber. The photovoltaic module 5 is conveyed through the auxiliary conveying strips 22. The second platform 32 is also provided with a plurality of vacuum suction cups 33 for fixing the position of the photovoltaic module 5 to ensure that the photovoltaic module 5 does not move when the pressure rod 318 defoams the photovoltaic module 5.

[0054] After the scraper 319 completes the defoaming of the photovoltaic module 5, the cavity door between the defoaming cavity 3 and the curing cavity 4 is raised, and the photovoltaic module 5 is conveyed from the cavity door to the curing cavity 4 by the auxiliary conveyor 22. Example 2

[0055] Please see Figure 11 In this embodiment, a turntable 34 is provided inside the defoaming chamber 3. The turntable 34 is provided with multiple vacuum suction cups 33. The position of the photovoltaic is fixed by the vacuum suction cups 33. The turntable 34 is controlled by a CNC system and can rotate. A hydraulic rod 311 is provided at the top of the defoaming chamber 3. A pressure rod 318 is provided at the bottom of the hydraulic rod 311. A scraper 319 is provided on the bottom surface of the pressure rod 318.

[0056] The rotation of the turntable 34 drives the photovoltaic module 5 to rotate. The hydraulic rod 311 adjusts its length according to the position of the photovoltaic module 5, so that the scraper 319 is in close contact with the surface of the photovoltaic module 5. When the turntable 34 drives the photovoltaic module 5 to rotate, the scraper 319 squeezes and defoams the photovoltaic module 5.

[0057] Please see Figure 12 The turntable 34 is equipped with multiple auxiliary conveyor bars 22. The turntable 34 has an opening at the location of each auxiliary conveyor bar 22. The structure and working principle of the auxiliary conveyor bars 22 are the same as those of the auxiliary conveyor bars 22 in the vacuum chamber 2. Before the turntable 34 rotates and after rotating one revolution, the conveying position of the auxiliary conveyor bars 22 is the same, which is horizontal. After the scraper bar 319 completes the defoaming of the photovoltaic module 5, the cavity door between the defoaming cavity 3 and the curing cavity 4 is raised, and the photovoltaic module 5 is conveyed from the cavity door by the auxiliary conveyor bars 22 to enter the curing cavity 4.

[0058] Process flow: After the laminated photovoltaic modules enter the vacuum chamber through the feeding door, the feeding door is closed, and the photovoltaic modules are placed on the first platform. The air inside the chamber is evacuated by the vacuum pump to form a vacuum environment. At the same time, the photovoltaic modules are heated by the heating system. When the vacuum degree and temperature reach the preset values, compressed air is injected into the upper chamber of the vacuum chamber, causing the pressure plate to begin to descend and laminate the photovoltaic modules.

[0059] After lamination, the photovoltaic module is transported to the defoaming chamber by the auxiliary conveyor bar. The photovoltaic module is placed on the second platform, and the surface of the photovoltaic module is rotated and pressed to defoam by the defoaming device, squeezing the bubbles out from the center of the photovoltaic module to the surrounding area, thus completing the bubble elimination.

[0060] After defoaming, the photovoltaic modules enter the curing chamber. The temperature inside the curing chamber is lowered by a temperature control system to achieve the curing effect, allowing the laminated photovoltaic modules to cool and solidify before being transported out from the outlet.

[0061] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0062] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A defoaming device, characterized by: Placed in the defoaming cavity of a photovoltaic module laminator, comprising: A power mechanism fixed to the defoaming cavity; A lever mechanism connected to the power mechanism and acting downward on the photovoltaic module (5); The top of the power mechanism is provided with a moving ring (313) which performs variable-diameter circumferential motion; The lever mechanism includes a connecting rod (314) having a small ball joint (315) at one end and a large ball joint (316) at the other end, the small ball joint (315) being arranged in the moving ring (313), and the large ball joint (316) being arranged in the power mechanism; The large ball joint (316) is provided at the bottom with a connecting arm (317), the end of the connecting arm (317) being hingedly connected with a pressing rod (318), and the end of the pressing rod (318) being provided with a scraping strip (319).

2. A photovoltaic module laminator characterized by: The laminator box (1) is divided into a vacuum cavity (2), a defoaming cavity (3) and a curing cavity (4) inside, the defoaming cavity (3) is provided with the defoaming device of claim 1.

3. A photovoltaic module laminator as claimed in claim 2, characterized in that: The vacuum cavity (2) is provided with a vacuum system, a heating system and a pressurizing system, and is divided into an upper cavity and a lower cavity, the lower cavity is provided with a first loading platform (21), the lower side of the first loading platform (21) is provided with a plurality of auxiliary conveying strips (22), each auxiliary conveying strip (22) includes two support frames (221), the two ends of each support frame (221) are provided with conveying rollers (222), the conveying rollers (222) are wound with conveying belts (223), the first loading platform (21) is provided with a hole at the corresponding position of each auxiliary conveying strip (22), and the top surface of the conveying belt (223) is flush with the top surface of the first loading platform (21).

4. A photovoltaic module laminator as claimed in claim 3, characterized in that: The vacuum system includes an air inlet (231) on the inner wall of the upper cavity and an air outlet (232) on the inner wall of the lower cavity, the air inlet (231) is controlled by an air pump, and the air outlet (232) is controlled by a vacuum pump.

5. A photovoltaic module laminator as defined in claim 3, wherein: The pressurizing system includes a pressing plate (241), the four edges of the pressing plate (241) are completely attached to the inner wall of the upper cavity, and the pressing plate (241) is connected to the top of the upper cavity by a plurality of spring rods (242).

6. A photovoltaic module laminator as defined in claim 3, wherein: The heating system includes an electric heater and a heat conducting pipe (25), the heat conducting pipe (25) is laid flat inside the first loading platform (21) and avoids the hole of the first loading platform (21).

7. A photovoltaic module laminator as defined in claim 2, wherein: The curing cavity (4) is provided with a conveying table (41) and a temperature control system.

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